Swappable battery modules comprising immersion-thermally controlled prismatic battery cells and methods of fabricating thereof

ABSTRACT

Described herein are swappable battery modules comprising immersion-thermally controlled prismatic battery cells and methods of operating thereof. A module comprises a tubular enclosure attached (e.g., glued) to different surfaces of the cells and forming two fluid channels with one side of the cells and two additional fluid channels with the opposite side. The module also comprises a first end plate, which is attached to the tubular enclosure and comprises two electrical terminals for connecting to an electric vehicle (EV) and/or external charger. The first end plate also comprises a first fluidic port (fluidically coupled with two fluid channels) and a second fluidic port (fluidically coupled to the remaining two fluid channels), both are configured to form fluidic coupling to the electric vehicle and/or the external charger. The module also comprises a second end plate that fluidically interconnects paid fluid channels from different cell sides.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit under 35 U.S.C. § 119(e) of U.S.Provisional Patent Application No. 63/489,488, filed on 2023 Mar. 10,which is incorporated herein by reference in its entirety for allpurposes.

BACKGROUND

Electric vehicles are propelled using electric motors powered by batterypacks. Each battery pack can include one or more battery modules, eachcomprising one or more battery cells. These cells can be connected inseries and/or parallel and controlled by a battery management system.While the operating temperature of battery cells depends on variousmaterials used to fabricate these cells (e.g., electrolyte solvents),most battery cells are designed to operate in the 0-60° C. range. Itshould be noted that battery cells can be very sensitive to theiroperating temperatures. For example, the power rating of battery cellscan drop quickly with the temperature (caused by lower ionic mobility).At the same time, battery cells degrade faster and can potentially enterunsafe conditions when operated at high temperatures.

In addition to various environmental conditions that can change cells'operating temperature, battery cells can generate considerable heatwhile charging and discharging, especially at high rates (that can bedesirable for many applications). For example, Joule heating caused bycells' internal resistance is one of the largest contributors. Othercontributors include but are not limited to electrode reactions andentropic heat generation caused by the insertion and de-insertion oflithium ions in and out of the electrodes. To maintain optimum operatingtemperatures, the heat must be removed from the battery cells as thisheat is being generated within the cells. It should be noted that othercomponents of battery packs (e.g., bus bars that interconnect batterycells) can also cause heating and should be also cooled wheneverpossible.

Liquid cooling or, more generally, liquid-based thermal management ofbattery cells is beneficial in comparison to, e.g., air cooling becauseof the large heat capacities and heat transfer coefficient of manyliquids in comparison to air. However, controlling the distribution ofliquid within battery packs can be challenging. For example, mostliquid-cooled battery packs have battery cells isolated from liquidpassages thereby preventing any direct contact between the cells andthermal fluid and relying on various heat-transferring componentspositioned in between. Furthermore, many liquid-cooled battery packsutilize cylindrical cells (e.g., 18650 cells) because of their smallfactor and ease of cooling (e.g., by thermal coupling to cell bottoms).However, battery packs with cylindrical cells tend to have lower energydensity because of their inherent packing density limitations.Additionally, most battery cooling systems focus on cooling batteriesand ignore bus bar cooling. At the same time, the bus bar cooling canprevent the overheating of bus bars and even allow using bus bars withsmaller cross-sections (for a given current). Finally, liquid-cooledbattery modules are generally stationary (e.g., permanently positionedon electric vehicles). At the same time, many applications (e.g.,smaller electric vehicles) can benefit from swappable batteries that,for example, can be charged remotely and that can also be liquid-cooled(e.g., while on the vehicle and/or on the external charger). However,forming/severing the liquid connections to a module in a fast andefficient manner can be challenging.

What is needed are new swappable battery modules comprisingimmersion-thermally controlled prismatic battery cells and methods offabricating thereof.

SUMMARY

Described herein are swappable battery modules comprisingimmersion-thermally controlled prismatic battery cells and methods ofoperating thereof. A module comprises a tubular enclosure attached(e.g., glued) to different surfaces of the cells and forming two fluidchannels with one side of the cells and two additional fluid channelswith the opposite side. The module also comprises a first end plate,which is attached to the tubular enclosure and comprises two electricalterminals for connecting to an electric vehicle (EV) and/or externalcharger. The first end plate also comprises a first fluidic port(fluidically coupled with two fluid channels) and a second fluidic port(fluidically coupled to the remaining two fluid channels), both areconfigured to form fluidic coupling to the electric vehicle and/or theexternal charger. The module also comprises a second end plate thatfluidically interconnects paid fluid channels from different cell sides.

In some examples, a swappable battery module comprises prismatic batterycells, bus bars, a tubular enclosure, a first end plate, and a secondend plate. The prismatic battery cells comprise a first-end cell and asecond-end cell. The prismatic battery cells are stacked along a primaryaxis of the swappable battery module between the first-end cell and thesecond-end cell. The prismatic battery cells comprise first surfaces,second surfaces opposite to the first surfaces, and side surfacesextending between the first surfaces and the second surfaces. Theprismatic battery cells comprise cell terminals positioned on the firstsurfaces. The bus bars form at least a first bus-bar row and a secondbus-bar row and interconnect the cell terminals. The tubular enclosureis attached to each of the first surfaces, the second surfaces, and theside surfaces of the prismatic battery cells. The tubular enclosureforms a first fluid channel and a second fluid channel with a portion ofthe first surfaces such that the first bus-bar row extends within thefirst fluid channel while the second bus-bar row extends within thesecond fluid channel. The tubular enclosure forms a third fluid channeland a fourth fluid channel with a portion of the second surface. Thefirst end plate is attached to the tubular enclosure and comprises afirst fluidic port fluidically coupled to both the first fluid channeland the third fluid channel and a second fluidic port fluidicallycoupled to both the second fluid channel and the fourth fluid channel.The first end also comprises a first electrical terminal and a secondelectrical terminal electrically coupled to the bus bars. The second endplate is attached to the tubular enclosure, fluidically interconnectsthe first fluid channel and the third fluid channel, and fluidicallyinterconnects the second fluid channel and the fourth fluid channel(independently from the first fluid channel and the third fluidchannel).

In some examples, the tubular enclosure comprises a first enclosureportion and a second enclosure portion, each independently attached toeach of the first surfaces, the second surfaces, and the side surfacesof the prismatic battery cells and further attached to each of the firstend plate and the second end plate. In some examples, the tubularenclosure further comprises an interconnecting portion, attached to eachof the first enclosure portion and the second enclosure portion andforming a gas-ventilation channel with the first surfaces of theprismatic battery cells. The prismatic battery cells comprisepressure-release burst valves positioned on the first surfaces and influid communication with the gas-ventilation channel. In some examples,the swappable battery module further comprises sensor wires,functionally coupled to each of the prismatic battery cells andprotruding within the gas-ventilation channel to the first end plate. Insome examples, the swappable battery module further comprises a handlecoupled to the tubular enclosure, proximate to the second surfaces ofthe prismatic battery cells such that prismatic battery cells arepositioned between the bus bars and the handle.

In some examples, a portion of the first end plate protrudes into and isglued to the tubular enclosure. Furthermore, a portion of the second endplate protrudes into and is glued to the tubular enclosure. In someexamples, the first end plate is glued to the first-end cell, while thesecond end plate is glued to the second-end cell. In some examples, thetubular enclosure is glued to each of the first surfaces, the secondsurfaces, and the side surfaces of each of the prismatic battery cells.The tubular enclosure is electrically isolated from each of theprismatic battery cells. In some examples, each adjacent pair of theprismatic battery cells is mechanically interconnected by an adhesivelayer extending between the prismatic battery cells in each adjacentpair. In some examples, the adhesive layer has an annulus shape.

In some examples, the bus bars form at least a third bus-bar row (e.g.,a return bus bar) extending within the second fluid channel. One of thebus bars in the first bus-bar row is electrically coupled to the firstelectrical terminal. One of the bus bars in the third bus-bar row iselectrically coupled to the second electrical terminal. In someexamples, each of the first bus-bar row and the second bus-bar rowcomprises multiple disjoined components. In more specific examples, eachof the multiple disjoined components comprises two planar portions andan interconnecting rib, joining the two planar portions. The two planarportions are connected to the cell terminals of two adjacent ones of theprismatic battery cells. The interconnecting rib protruding from the twoplanar portions and in a direction away from the prismatic battery cellsand comprises one or fluid path openings.

In some examples, the first end plate comprises a center protrusion andtwo side edges, extending along the side surfaces of the first-end cell.The two side edges and the center protrusion from edge channelsfluidically coupling the first fluid channel and the third fluid channeland, separately, fluidically coupling the second fluid channel and thefourth fluid channel.

In some examples, the swappable battery module further comprises sensorwires functionally coupled to each of the prismatic battery cells. Theswappable battery module also comprises a battery management system,electronically coupled to each of the sensor wires. The first end platecomprises an outer cavity such that the battery management system ispositioned with the outer cavity. The first end plate further comprisesa passthrough such that the sensor wires protrude through thepassthrough and are sealed within the passthrough.

In some examples, the second end plate comprises a first cavityfluidically coupling the first fluid channel and the second fluidchannel. The second end plate further comprises a second cavityfluidically coupling the third fluid channel and the fourth fluidchannel.

In some examples, each of the first fluidic port and the second fluidicport is configured to form a fluidic coupling with a correspondingfluidic port on one or both of an electrical vehicle and an externalcharger. For example, the fluidic coupling comprises a first componentand a second component, configured to form a sealed fluidically couplingwith each other in a coupled state and to disconnect from each otherwhile transitioning into a decoupled state. The first componentcomprises a first body, a first seal, a first spool, a first spool seal,a slider, a first slider seal, and a first spring. The first spool isslidably coupled to the first body and to the slider and biased,relative to the first body, by the first spring. The first spool issealed against the first body by the first seal. The second componentcomprises a second body, a second seal, a second spool, and a secondspring. The second spool is slidably coupled to and biased, by thesecond spring, relative the second body. When the fluidic coupling is inthe coupled state, the first spool extends into the second body and issealed against the second body by the second seal. When the fluidiccoupling is in the decoupled state, the first spool is sealed relativeto the slider by the first slider seal while the second spool is sealedrelative to the second body by the second seal. In some examples, eachof the first fluidic port and the second fluidic port is the secondcomponent of the fluidic coupling.

Also provided a method of operating a swappable battery module. In someexamples, the method comprises positioning the swappable battery moduleon an external charger comprising charger fluidic ports. The swappablebattery module comprises prismatic battery cells, a tubular enclosure,attached to and enclosing the prismatic battery cells, a first end plateattached to the tubular enclosure, and a second end plate attached tothe tubular enclosure. The tubular enclosure forms a first fluidchannel, a second fluid channel, a third fluid channel, and a fourthfluid channel with the prismatic battery cells. The first end platecomprises a first fluidic port, fluidically coupled to both the firstfluid channel and the third fluid channel, and a second fluidic port,fluidically coupled to both the second fluid channel and the fourthfluid channel. The second end plate fluidically interconnects the firstfluid channel and the third fluid channel and, separately, fluidicallyinterconnects the second fluid channel and the fourth fluid channel. Insome examples, the method also comprises sliding the first end platetoward the charger fluidic ports until the charger fluidic ports arefluidically coupled with the first fluidic port and the second fluidicport.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a system comprising an electric vehicle, anexternal charger, and a swappable battery module that can beinterchangeably connected to either the electric vehicle or the externalcharger, in accordance with some examples.

FIG. 2A is a block diagram of a swappable battery module, in accordancewith some examples.

FIG. 2B is a schematic illustration of a swappable battery modulecomprising immersion-thermally controlled battery cells, in accordancewith some examples.

FIG. 2C is a schematic perspective view of a stack of prismatic batterycells for use in a swappable battery module, in accordance with someexamples.

FIG. 2D is a schematic perspective view of the prismatic battery cellsin FIG. 2C with three sets of bus bars attached to the cells, inaccordance with some examples.

FIG. 2E is a schematic expanded view of FIG. 2D illustrating twodisjoined bus bar components, in accordance with some examples.

FIG. 2F is a schematic top view of the prismatic battery cells in FIG.2C with two sets of bus bars (and no return bus bar) attached to thecells, in accordance with some examples.

FIG. 2G is a schematic cross-sectional view of a swappable batterymodule illustrating fluidic channels formed by the tubular enclosure andcells, in accordance with some examples.

FIGS. 2H and 2I are schematic views of a swappable battery moduleillustrating fluidic pathways through the module, in accordance withsome examples.

FIGS. 2J and 2K are schematic perspective front and back views of afirst end plate, in accordance with some examples.

FIG. 2L is a schematic perspective view of a second end plate, inaccordance with some examples.

FIGS. 3A and 3B are schematic cross-sectional side views of a fluidiccoupling comprising a first component and a second component, one ofwhich can be operable as a fluidic port of a swappable battery module,in a coupled state (FIG. 3A) and a decoupled state (FIG. 3B) inaccordance with some examples.

FIG. 4 is a process flowchart of a method for operating a batterymodule, in accordance with some examples.

FIGS. 5A-5F are schematic cross-sectional side views of a fluidiccoupling at different stages while decoupling the first component fromthe second component, in accordance with some examples.

FIGS. 6A and 6B are schematic views of an external charger and onebattery module connected to the charger, in accordance with someexamples.

FIGS. 6C-6E are schematic side views of an external charger at variousstages while connecting a battery module to the charger, in accordancewith some examples.

DETAILED DESCRIPTION

In the following description, numerous specific details are outlined toprovide a thorough understanding of the present invention. The presentinvention may be practiced without some or all of these specificdetails. In other instances, well-known process operations have not beendescribed in detail to avoid obscuring the present invention. While theinvention will be described in conjunction with the specific examples,it will be understood that it is not intended to limit the invention tothe examples.

Introduction

As noted above, battery cells can be very sensitive to operatingtemperatures. At the same time, these temperatures can be influenced bythe environment and/or by the cells' operation (e.g., self-heatingduring fast charge/discharge). Liquid-based thermal management providesefficient ways for controlling the temperature of battery cells.However, the thermal coupling of battery cells and thermal fluid can bechallenging. The immersion cooling of battery cells brings battery cellsin direct contact with thermal fluids, which is beneficial for thermaltransfer (in comparison to positioning intermediate structures betweenthe cells and thermal fluids, e.g., to enclose the thermal fluid). Thekey challenges include controlling the distribution and flow of thermalfluids around battery cells and other components (e.g., bus bars).

Described herein are battery modules comprising immersion-thermallycontrolled prismatic battery cells and methods of operating thereof.Specifically, each battery cell comes in direct contact with a thermalfluid (e.g., transformer oil) at multiple locations, e.g., two locationson the first surface of these battery cells and two additional locationson the second surface, opposite of the first surface. Furthermore, thethermal fluid is circulated in such a way that all experiencesubstantially the same heat transfer driven by the temperaturedifference between the cells and fluid. Furthermore, even when thethermal fluid is not circulated, the fluid remaining in the batterymodule provides an additional thermal mass and thermal pathways betweenthe cells and other components of the battery modules. For example, atcertain operating conditions (e.g., discharge/charge rates of at or lessthan 5 C, at or less than 2 C, or even at or less than 1 C), nocirculation of the thermal fluid may be provided. Specifically, no fluidcirculating may be provided while a batter module is positioned on avehicle. However, at higher discharge/charge rates (e.g. at or greaterthan 5 C, at or greater than 8 C, or even at or greater than 10 C), thethermal fluid can be circulated through the module (e.g., when themodule is connected to an external charger thereby enabling high chargerates). Specifically, the thermal fluid may be circulated through thebattery module as well as between the module and an external coolingsystem, wherein the thermal fluid is cooled before being returned to themodule. It should be noted that immersion-thermally control may involvecooling and/or heating.

In some examples, battery cells are glued together for the structuralintegrity of the resulting battery module. The adhesive layers providedbetween the cells can also be used for the electrical isolation ofbattery cells and, to some extent, for the thermal isolation of thecells (both of which are safety measures). Furthermore, the directattachment of the battery cells effectively provides some internalstructural support (e.g., a module skeleton) and reduces the structuralrequirements from the external components, thereby reducing theweight/size of these components (and increasing thegravimetric/volumetric capacity of the module). The external support isprovided by an enclosure.

Battery modules described herein can be used to power electric vehiclesand can be charged using external chargers. FIG. 1 is a schematic blockdiagram illustrating battery module 120 being swapped between electricvehicle 100 (to power electric vehicle 100) and external charger 180 (torecharge battery module 120). Hence battery module 120 may be alsoreferred to as a swappable battery module 120. For purposes of thisdisclosure, the terms “battery module” and “swappable battery module”are used interchangeably. Furthermore, battery module 120 may be alsoreferred to as an immersion-thermally controlled battery module sincethe cells within the module are in direct contact with the thermal fluidas described below.

While on electric vehicle 100, battery module 120 is electricallyconnected to vehicle power system 102, e.g., inverters, electric motors,and other like devices. Various types of electric vehicles 100 (e.g.,tractors, rugged terrain vehicles (RTVs), all-terrain vehicles (ATVs),industrial electric vehicles such as loaders, forklifts, and the like)are within the scope. In some examples, battery module 120 can also befluidically connected to vehicle thermal management system 110, whichallows circulating thermal fluid 105 between vehicle thermal managementsystem 110 and battery module 120. Vehicle thermal management system 110is optional and, in some examples, battery module 120 does not form anyfluidic connections to any systems on electric vehicle 100. When such aconnection is formed, the circulation of thermal fluid 105 can be usedto control the temperature of battery module 120 or, more specifically,the temperature of the battery cells forming this battery module 120.For example, electric vehicle 100 (e.g., snowmobiles, ATVs) can beoperated at environmental temperatures that are outside of the desiredcell temperature range. In the same or other examples, the power demandfrom vehicle power system 102 can cause significant heating of thebattery cells (e.g., exceeding the environmental cooling rate of batterymodule 120). Vehicle thermal management system 110 can be configured toprovide thermal fluid 105 at a desired temperature range (e.g., between10° C. and 30°) to assist with cooling and/or heating of battery module120. In some examples, vehicle thermal management system 110 is equippedwith one of a heat pump, a heater, a radiator, and the like.

While on external charger 180, battery module 120 is electricallyconnected to charger power system 182. In some examples, battery module120 can also be fluidically connected to charger thermal managementsystem 190. Charger thermal management system 190 is optional and, insome examples, battery module 120 does not form any fluidic connectionsto any systems on external charger 180. When such a connection isformed, this connection allows circulating thermal fluid 105 betweencharger thermal management system 190 and battery module 120. As notedabove, this circulation of thermal fluid 105 can be used to control thetemperature of battery module 120 or, more specifically, the temperatureof the battery cells forming this battery module 120. In addition toenvironmental temperature considerations, this circulation allows usinghigh charge rates (e.g., greater than 2 C, greater than 5 C, and even ashigh as 10 C or greater) without the risk of overheating the cells.Charge currents (similar to discharge currents) caused the internal cellheating. The circulation of thermal fluid 105 allows for the efficientremoval of this generated heat thereby allowing higher charge rates andfaster charging. In some examples, charger thermal management system 190is equipped with one of a heat pump, a heater, a radiator, and the like.Examples of fluidic connections are described below with reference toFIGS. 5A-5F.

Battery module 120 comprises electrical terminals 240 to form theabove-referenced electrical connections. The same set of electricalterminals 240 is used for connection to both vehicle power system 102and charger power system 182. Furthermore, battery module 120 comprisesfluidic ports 250 to form the above-referenced fluidic connections,e.g., to at least one of vehicle thermal management system 110 andcharger thermal management system 190. These and other features ofbattery module 120 will now be described with reference to FIGS. 2A-2Land FIG. 3A-3B.

Examples of Swappable Immersion-Thermally Controlled Battery Modules

FIG. 2A is a block diagram of swappable battery module 120, illustratingvarious module components as well as mechanical and functionalconnections among these components, in accordance with some examples.FIG. 2B is a schematic perspective view of swappable battery module 120in FIG. 2A. Battery module 120 comprises immersion-thermally controlledbattery cells 130 forming one or more stacks inside battery module 120.Specifically, in the view of FIG. 2B, prismatic battery cells 130(schematically identified using dashed lines) are hidden by othercomponents such as tubular enclosure 170, first end plate 150, andsecond end plate 160. A combination of tubular enclosure 170, first endplate 150, and second end plate 160 enclose prismatic battery cells 130and isolate prismatic battery cells 130 from the environment.Furthermore, this combination of tubular enclosure 170, first end plate150, and second end plate 160 provide the immersion thermal control toprismatic battery cells 130 by containing thermal fluid 105 withinvarious fluid channels formed by these components and prismatic batterycells 130 as further described below.

FIG. 2C is a schematic perspective view of a stack of prismatic batterycells 130, in accordance with some examples. Specifically, tubularenclosure 170, first end plate 150, and second end plate 160 are notshown in FIG. 2C. One having ordinary skill in the art would understandthat any number of cells can be used in one battery module 120. Batterycells 130 used in battery module 120 are prismatic, rather thancylindrical. Prismatic battery cells 130 can be packed more compactly(with fewer spaces in between cells) within battery module 120 resultingin a higher density of battery module 120. For purposes of thisdescription, a prismatic battery cell is defined as a cell having ashape of a rectangular prism (as opposed to a cylinder). As such, aprismatic battery cell has three distinct dimensions: (a) height, (b)width, and (c) thickness. In some examples, the height of prismaticbattery cell 130 (used in battery module 120) is between 50 millimetersand 200 millimeters or, more specifically, between 75 millimeters and125 millimeters. In the same or other examples, the width of prismaticbattery cell 130 (used in battery module 120) is between 50 millimetersand 200 millimeters or, more specifically, between 75 millimeters and125 millimeters. In some examples, the thickness of prismatic batterycell 130 (used in battery module 120) is between millimeters and 50millimeters or, more specifically, between 10 millimeters and 30millimeters. The number and size of battery cells 130 also define thesize and weight of battery module 120. In some examples, battery module120 has a weight of between 5 kilograms and 50 kilograms or, morespecifically, between 10 kilograms and 40 kilograms, such as between 15kilograms and 30 kilograms. While a heavier module can provide morecharge energy, it is much harder to handle and swap heavier modules. Ingeneral, the weight of battery module 120 is selected to be swappable bya human.

Prismatic battery cells 130 can be of various chemistry types, e.g.,nickel-manganese-cobalt (NMC), lithium iron phosphate (LFP), and lithiumtitanate (LTO), at least based on the composition of positiveelectrodes. For example, lithium titanate (LTO) cells can support highcharge-discharge rates, which may be particularly useful for industrialapplications such as electric tractors, loaders, and the like.

Referring to FIGS. 2B and 2C, prismatic battery cells 130 are stackedalong primary axis 129 of battery module 120 (which extendssubstantially parallel to the X-axis in these figures). While FIG. 2Cillustrates one cell stack, the same battery module 120 may includemultiple different cell stacks (e.g., positioned next to each other).Prismatic battery cells 130 comprise first surfaces 131, second surfaces132 opposite to first surfaces 131, and side surfaces 133 extendingbetween first surfaces 131 and second surfaces 132. For example, eachfirst surface 131, second surface 132, and side surface 133 can besubstantially parallel to primary axis 129. In some examples, each ofprismatic battery cells 130 has a height, length, and thickness suchthat the thickness is less than the height and less than the length andsuch that the thickness is parallel to primary axis 129 of batterymodule 120. Prismatic battery cells 130 can be stacked along theirthicknesses.

Prismatic battery cells 130 also comprise cell terminals 134 positionedon first surfaces 131. Cell terminals 134 are used to form electricalconnections to prismatic battery cells 130. In some examples, cellterminals 134 are isolated from the other external components (e.g., thecase, lid) of prismatic battery cells 130 such that these components areneutral. In some examples, prismatic battery cells 130 comprisepressure-release burst valves 136 configured to release gases from theinterior of prismatic battery cells 130 when the pressure insideprismatic battery cells 130 exceeds a set threshold. In more specificexamples, pressure-release burst valve 136 of each prismatic batterycell 130 is positioned between cell terminals 134 of that cell.

Referring to FIGS. 2C and 2I, in some examples, two adjacent prismaticbattery cells 130 are mechanically interconnected by adhesive layer 138extending between prismatic battery cells 130 in each adjacent pair.Some examples of adhesive layer 138 include but are not limited to epoxyand polyurethane. The thickness of adhesive layer 138 can be used toaccommodate variations in the cell thicknesses. For example, a pair ofthin cells may have a thicker adhesive layer, while a pair of thickcells may have a thinner adhesive layer, such that the combinedthickness is the same regardless of the cell thicknesses. Furthermore,flexible adhesives can be compressible and used to accommodate cellswelling (if any) during the operation of battery module 120. In someexamples, adhesive layers 138 also provide electrical insulationsbetween adjacent cells (e.g., even though the sides of battery cells 130can be substantially neutral). In these examples, adhesive layers 138are continuous sheets extending between battery cells 130 to tubularenclosure 170. Alternatively, adhesive layers 138 have an annulus shape,e.g., as shown in FIG. 2I to accommodate swelling of prismatic batterycells 130 that tend to swell more in the center/away from the edges.

Adhesive layers 138 provide attachment/bonding between prismatic batterycells 130 in the set adding to the overall structural integrity ofbattery module 120. In other words, a combination of prismatic batterycells 130 and adhesive layers 138 is operable as an internal structuralelement (which can be referred to as a “skeleton”) of battery module120. Other components of battery module 120, e.g., first end plate 150,second end plate 160, and tubular enclosure 170 are operable as aninternal structural element (“exoskeleton”). Furthermore, adhesivelayers 138 provide electrical isolation and, in some examples, thermalisolation of adjacent prismatic battery cells 130. While the cases ofprismatic battery cells 130 can be neutral, the electrical isolation canhelp to improve the overall module safety (e.g., when internal shortsdevelop in one or more prismatic battery cells 130).

Referring to FIGS. 2D-2E, battery module 120 comprises bus bars 140interconnecting cell terminals 134. Bus bars 140 can be made fromcopper, aluminum, nickel, and other suitable conductive materials. WhileFIGS. 2D and 2F illustrate one example of cell connections (i.e., 17sconnection scheme, in which each 17 prismatic battery cells 130 areinterconnected in series), other examples are also within the scope. Theconnection scheme depends on the required voltage output of batterymodule 120 and other like factors.

In some examples, bus bars 140 comprise a plurality of disjoinedcomponents 144, forming first bus-bar row 141 and second bus-bar row142, e.g., as shown in FIG. 2E where return bus bar 143 is notshown/hidden). Furthermore, bus bars 140 can include return bus bar 143,used for positioning both electric terminals of battery module 120 onthe same side (e.g., first end plate 150). Return bus bar 143 can beconnected to one cell (e.g., second-end cell 139 in FIG. 2D) and oneelectric terminal (not shown in FIG. 2D). Return bus bar 143 extendsover battery cells 130 without making any other electrical connectionsto battery cells 130 or other components of bus bars 140.

Referring to FIG. 2E, in some examples, one example of disjoinedcomponents 144 comprises two planar portions 145 and interconnecting rib146, joining two planar portions 145. Two planar portions 145 areconnected to cell terminals 134 of two adjacent battery cells 130.Interconnecting rib 146 can protrude from two planar portions 145 and inthe direction away from battery cells 130, e.g., to provide in-planemovement flexibility between planar portions 145 (e.g., along the X-axisto accommodate the swelling of adjacent battery cells 130 correspondingto changing the distance between the attachment points between thesecells and planar portions 145. It should be noted that interconnectingrib 146 protrudes into a fluidic channel and can (at least partially)block the fluidic path. As such, interconnecting rib 146 comprises oneor fluid path openings 147 to assist with this flow. Furthermore,interconnecting rib 146 can assist with the mixing of thermal fluid 105within the channel thereby enhancing the thermal transfercharacteristics.

Referring to FIG. 2F, bus bars 140 in first bus-bar row 141 areconnected to cell terminals 134 having one polarity (e.g., positive cellterminals), while bus bars 140 in second bus-bar row 142 are connectedto cell terminals 134 having the other polarity (e.g., negative cellterminals). Further connections are provided through battery cells 130.Since cell terminals 134 are positioned on first surfaces 131 (in theexample shown in FIG. 4 ), bus bars 140 are also positioned next tofirst surfaces 131.

It should be noted that during the operation of battery module 120, busbars 140 are immersion-thermally controlled as further described below.As such, the cross-section of bus bars 140 can be reduced in comparisonto bus bars that are not thermally controlled thereby allowing someresistive heating within bus bars 140. For example, the temperaturecoefficient of copper is about 0.00404 C⁻¹. Therefore, increasing thetemperature of copper bus bars by 50° C. will cause the resistivity toincrease by about 20%. Without the temperature control of bus bars 140,the dimensions of bus bars 140 need to accommodate the highest operatingtemperature. It should be noted that the heating of bus bars 140 can becaused by receiving the heat from battery cells 130 and also from theinternal resistive heating. However, increasing the size of bus bars 140(to accommodate for higher operating temperatures) is highly undesirablesince this increases the weight and size of bus bars 140 (and as aresult of battery module 120). Furthermore, bus bars 140 can be used (inaddition to thermal fluid 105) for transferring the heat between batterycells 130.

Referring to FIG. 2G, tubular enclosure 170 is attached to each of firstsurfaces 131, second surfaces 132, and side surfaces 133 of prismaticbattery cells 130. Tubular enclosure 170 forms first fluid channel 121and second fluid channel 122 with a portion of first surfaces 131.Similarly, tubular enclosure 170 forms third fluid channel 125 andfourth fluid channel 126 with a portion of second surfaces 132. Thesefluid channels are used for circulating thermal fluid 105 throughbattery module 120 and, more specifically, for direct contact betweenthermal fluid 105 and prismatic battery cells 130 thereby establishingimmersion thermal transfer between thermal fluid 105 and prismaticbattery cells 130 (e.g., immersion cooling).

Overall, each prismatic battery cell 130 is immersed/comes in contactwith the thermal fluid provided in all four fluid channels, i.e., firstfluid channel 121, second fluid channel 122, third fluid channel 125,and fourth fluid channel 126. Each prismatic battery cell 130 isthermally controlled (e.g., immersion-cooled and/or immersion-heated)from first surface 131 and second surface 132 thereby ensuring more auniform temperature profile within prismatic battery cell 130 (e.g., incomparison to one-sided cooling of battery cells). Furthermore, firstfluid channel 121 and second fluid channel 122 are also used for coolingbus bars 140. For example, first bus-bar row 141 protrudes into firstfluid channel 121 while second bus-bar row 142 protrudes into secondfluid channel 122.

FIG. 2H illustrates one example of the fluidic flow paths within batterymodule 120. Specifically, first end plate 150 comprises first fluidicport 251 and second fluidic port 252. Thermal fluid 105 can enterbattery module 120 through first fluidic port 251. First fluidic port251 is fluidically coupled to both first fluid channel 121 and thirdfluid channel 125. Thereby, thermal fluid 105 is directed from firstfluidic port 251 in both first fluid channel 121 and third fluid channel125. When thermal fluid 105 flows through first fluid channel 121,thermal fluid 105 comes in contact with first surfaces 131 of batterycells 130 (or, more specifically, portions of these surfaces).Similarly, when thermal fluid 105 flows through third fluid channel 125,thermal fluid 105 comes in contact with second surfaces 131 of batterycells 130 (or, more specifically, portions of these surfaces). Oncethermal fluid 105 reaches second end plate 160, a portion of thermalfluid 105 from first fluid channel 121 is redirected to second fluidchannel 122, while the other portion of thermal fluid 105 from thirdfluid channel 125 is redirected to fourth fluid channel 126. As furtherdescribed below, second end plate 160 fluidically interconnects firstfluid channel 121 and third fluid channel 125. Second end plate 160 alsofluidically interconnects second fluid channel 122 and fourth fluidchannel 126 (independently from first fluid channel 121 and third fluidchannel 125). Thermal fluid 105 then flows through second fluid channel122 and again comes in contact with first surfaces 131 of battery cells130 (now with different portions of these surfaces). Similarly, theother portion of thermal fluid 105 flows through fourth fluid channel126 and comes in contact with second surfaces 131 of battery cells 130(again with different portions of these surfaces). Second fluidic port252 is fluidically coupled to both second fluid channel 122 and fourthfluid channel 126 and receives thermal fluid 105 from both of thesechannels, after which thermal fluid 105 is discharged from batter module120 through second fluidic port 252.

Referring to FIG. 2I, as the thermal fluid having an inlet temperature(T_(in)) enters battery module 120, the thermal fluid receives the heat(H₁) and increases the fluid temperature as the fluid continues to flowthrough the module. For example, upon reaching the last cell in thisseries (second-end cell 139), the fluid temperature (T_(x)) will behigher than the inlet temperature (T_(x)>T_(in)). Assuming that allbattery cells have the same temperature (T_(cell)), the first cell(first-end cell 137) that comes in contact with the immediately incoming(colder) fluid will lose more heat than any subsequent cell in thisseries since the heat transfer is proportional to the temperaturegradient between the cell and the fluid. For example, the heat transferfrom the last cell in this series (H_(x)∝T_(cell)−T_(x)) will be smallerthan the heat transfer from the first cell in this series(H₁∝T_(cell)−T_(in)) due to the thermal fluid heating and the thermalgradient reduction (T_(in)<T_(x)→H₁>H_(x)). If the thermal fluid is notlooped and allowed to exit on the other side of the battery module, thenthe first cell will be cooled more than the last cell. However, when thethermal fluid is looped and has both first fluid channel 121 and secondfluid channel 122 (both providing fluidic contact to each cell), thereis additional heat transfer occurs from each cell. Specifically, theheat transfer provided by first fluid channel 121 is described aboveresulting in the first cell will be cooled more than the last cell.However, as the thermal fluid is directed from first fluid channel 121to second fluid channel 122, the order of the cell experiencing the flowis flipped while the thermal fluid continues to heat. The last cell seesthis return flow first and experiences additional heat transfer(H′_(x)∝T_(cell)−T′_(x)). The first cell sees this return flow last andalso experiences additional heat transfer (H′₁∝T_(cell)−T_(out)). Sincethe thermal fluid continues to heat (T_(out)>T′_(x)), the last cell isnow cooled more (H′_(x)>H′₁). Combining the two heat transfers (providedby first fluid channel 121 to second fluid channel 122), the total heattransfer is more balanced (H_(x)+H′_(x)˜H₁+H′₁) than the heat transferprovided by each of the channels individually. While the above exampleis provided for cells' cooling, one having ordinary skill in the artwould understand how the same concept applies to cells' heating.

Returning to FIG. 2G, first fluid channel 121 and third fluid channel125 are formed by tubular enclosure 170 with a portion of first surfaces131. Similarly, third fluid channel 125 and fourth fluid channel 126 areformed by tubular enclosure 170 with a portion of second surfaces 132.In this example, first bus-bar row 141 extends within first fluidchannel 121. In other words, both first surfaces 131 of battery cells130 and first bus-bar row 141 can be thermally controlled (e.g., cooledand/or heated) while thermal fluid 105 flows through third fluid channel125. First bus-bar row 141 is connected to cell terminal 134. A portionof tubular enclosure 170 can be protected from contacting first bus-barrow 141 and cell terminal 134 by an insulator, thereby maintaining theelectric neutrality of tubular enclosure 170. In this illustratedexample, second bus-bar row 142 extends within second fluid channel 122.Furthermore, return bus bar 143 (if one is present) can extend througheither first fluid channel 121 or second fluid channel 122. Return busbar 143 may be operable as a return bus bar as described above.

Referring to FIG. 2G, in some examples, tubular enclosure 170 comprisesfirst enclosure portion 171 and second enclosure portion 172, eachindependently attached to each of first surfaces 131, second surfaces132, and side surfaces 133 of prismatic battery cells 130. Each of firstenclosure portion 171 and second enclosure portion 172 is alsoindependently attached to each of first end plate 150 and second endplate 160 (not shown in FIG. 2F). Each of first enclosure portion 171and second enclosure portion 172 can be independent monolithiccomponents (e.g., a shaped metal sheet). However, these portions are notmonolithic with each other. Separating tubular enclosure 170 into firstenclosure portion 171 and second enclosure portion 172 simplified theassembly of battery module 120, e.g., positioning battery cells 130 withtubular enclosure 170. In some examples, each of first enclosure portion171 and second enclosure portion 172 is glueded to each of firstsurfaces 131, second surfaces 132, and side surfaces 133 of prismaticbattery cells 130. Similarly, each of first enclosure portion 171 andsecond enclosure portion 172 can be glueded to each of first end plate150 and second end plate 160.

Referring to FIG. 2G, in some examples, tubular enclosure 170 furthercomprises interconnecting portion 173, attached to each of firstenclosure portion 171 and second enclosure portion 172 and forminggas-ventilation channel 177 with first surfaces 131 of prismatic batterycells 130. Interconnecting portion 173 effectively interconnects(bridges) first enclosure portion 171 and second enclosure portion 172while extending above first surfaces 131 of prismatic battery cells 130.In some examples, interconnecting portion 173 is glued to each of firstenclosure portion 171 and second enclosure portion 172. As noted above,prismatic battery cells 130 comprise pressure-release burst valves 136positioned on first surfaces 131. These pressure-release burst valves136 are in fluid communication with gas-ventilation channel 177.

In case one or more prismatic battery cells 130 experience internalover-pressurization, the corresponding pressure-release burst valves 136open and release internal gases (and possibly other matter) from thesecells into gas-venting channel 177 thereby allowing to depressurize thecells. In some examples, gas-venting channel 177 is fluidically isolatedfrom other components, e.g., bus bars 140, thereby preventing furtherpropagation of unsafe conditions and even potentially continuing theoperation of battery module 120. In some examples, one or both of firstend plate 150 and second end plate 160 comprises burst valves to ventgases from battery module 120 (e.g., when the pressure insidegas-venting channel 177 exceeds a set threshold).

In some examples, swappable battery module 120 further comprises sensorwires 127, functionally coupled to each of prismatic battery cells 130and protruding within gas-ventilation channel 177 to first end plate150. For example, sensor wires 127 can be coupled to cell terminals 134and/or bus bar portions (e.g., used for voltage sensing) and/or tothermocouples and/or other sensors disposed inside battery module 120.Sensor wires 127 can extend to first end plate 150 for connecting tobattery management system 128 and/or forming one or more externalconnections.

In some examples, battery module 120 comprises handle 178, e.g., forcarrying battery module 120 between electric vehicle 100 and externalcharger 180. Handle 178 is coupled (e.g., glued) to tubular enclosure170 or, more specifically, interconnecting portion 173, e.g., as shownin FIG. 2G. In other examples, handle 178 is coupled (e.g., glued) tothe side of tubular enclosure 170, which is opposite of interconnectingportion 173/gas-ventilation channel 177. More specifically, handle 178is coupled to the side of tubular enclosure 170 adjacent to secondsurfaces 132 of battery cells 130. In these examples, when batterymodule 120 is not fluidically coupled to either electric vehicle 100 orexternal charger 180, the residual thermal fluid 105 still occupiesfirst fluid channel 121 and second fluid channel 122 thereby helping tomaintain bus bars 140 inside this residual thermal fluid 105 (e.g.,additional thermal mass and/or thermal conductivity to other packcomponents provided this by residual thermal fluid 105). It should benoted that the installation orientation (relative to the gravitationaldirection) of battery module 120 on electric vehicle 100 and externalcharger 180 is such that handle 178 faces up while the residual thermalfluid 105 will be at the bottom of battery module 120. It should be alsonoted that battery module 120 can also be used under some operatingconditions (e.g., low currents) without being fluidically coupled andwithout circulating thermal fluid 105 inside battery module 120. Inthese examples, the residual thermal fluid 105 still assists with theheat dissipation with battery module 120. In some examples, anotherhandle can be attached to second end plate 160 and is used during theinstallation of battery module 120 on electric vehicle 100 and externalcharger 180.

Referring to FIGS. 2J and 2K, in some examples, first end plate 150comprises two electrical-terminal openings 153 (for installing firstelectrical terminal 241 and second electrical terminal 242—not shown inFIGS. 2J and 2K) and two fluid-port openings 154 (for installing firstfluidic port 251 and second fluidic port 252—not shown in FIGS. 2J and2K). Ins some examples, first fluidic port 251 and second fluidic port252 are positioned further away from the side edges of first end plate150 than the corresponding first electrical terminal 241 and secondelectrical terminal 242. Alternatively, first fluidic port 251 andsecond fluidic port 252 are positioned closer to the side edges of firstend plate 150 than the corresponding first electrical terminal 241 andsecond electrical terminal 242.

In some examples, first end plate 150 comprises center protrusion 157and two side edges 156. In battery module 120 side edges 156 extendalong side surfaces 133 of first-end cell 137. Referring to FIG. 2K, twoside edges 156 and center protrusion 157 from edge channels 158fluidically coupling first fluid channel 121 and third fluid channel 125and, separately, fluidically coupling second fluid channel 122 andfourth fluid channel 126.

Referring to FIG. 2J, in some examples, first end plate 150 comprisesouter cavity 155 such that battery management system 128 is positionedwith outer cavity 155 (e.g., as shown in FIG. 2B). First end plate 150also comprises passthrough 159 such that sensor wires 127 protrudethrough passthrough 159 and are sealed within passthrough 159.

In some examples, first end plate 150 comprises side walls 150-1extending between first-end-plate outer surface 151 and first-end-plateinner surface 152. At least a portion of these side walls 150-1 canextend into and can be attached (e.g., glued and sealed) to tubularenclosure 170. In some examples, fasteners are used for connecting firstend plate 150 tubular enclosure 170. In some examples, first end plate150 is also glued to first-end cell 137.

Referring to FIG. 2L, in some examples, second end plate 160 comprisesfirst cavity 162 fluidically coupling first fluid channel 121 and secondfluid channel 122. Second cavity 164 fluidically couples third fluidchannel 125 and fourth fluid channel 126. In battery assembly, secondend plate 160 is attached to tubular enclosure 170, fluidicallyinterconnecting first fluid channel 121 and third fluid channel 125, andfluidically interconnecting second fluid channel 122 and fourth fluidchannel 126. For example, a portion of second end plate 160 protrudesinto and is glued to tubular enclosure 170. In some examples, second endplate 160 is also glued to second-end cell 139.

In some examples, each of first fluidic port 251 and second fluidic port251 is configured to form fluidic coupling 300 with a correspondingfluidic port on one or both of electrical vehicle 100 and externalcharger 180. One example of fluidic coupling 300 is shown in FIGS. 3Aand 3B. Specifically, fluidic coupling 300 comprises first component 301and second component 302, configured to form a sealed fluidicallycoupling with each other in a coupled state (FIG. 3A) and to disconnectfrom each other while transitioning into a decoupled state (FIG. 3B).Either first component 301 or second component 302 can be operable aseach of first fluidic port 251 and second fluidic port 251. When firstcomponent 301 is used as a fluidic port of battery module, secondcomponent 302 is used to electric vehicle 100 and/or external charger180. Alternatively, when second component 302 is used as a fluidic portof battery module 120, first component 301 is used to electric vehicle100 and/or external charger 180. It should be noted that secondcomponent 302 has a lower profile (no protrusions beyond its main body)thereby making second component 302 more suitable as a fluidic port ofbattery module 120

Referring to FIGS. 3A and 3B, first component 301 comprises first body310, first spool 320, first spool seal 325, slider 340, first sliderseal 345, and first spring 350. First spool 320 is slidably coupled tofirst body 310 and also to slider 340. First spool 320 is also biased,relative to first body 310, by first spring 350 (e.g., in the directionof second component 302). First spool 320 is sealed against first body360 by second seal 365, which allows first spool 320 to slide relativeto first body 360.

Second component 302 comprises second body 360, second seal 365, secondspool 370, and second spring 380. Second spool 370 is slidably coupledto and biased, by second spring 380, relative to second body 360.Specifically, second spool 370 is biased in the direction of firstcomponent 301.

When fluidic coupling 300 is in the coupled state, e.g., as shown inFIG. 3A, first spool 320 extends into second body 360 and is sealedagainst second body 360 by second seal 365. At the same time, firstspool 320 is sufficiently retracted into first body 310 allowing slider340 to extend past first spool 320 and into second body 360. Slider 340comprises slider opening 343 which allows thermal fluid 105 to flow frombetween the cavity inside slider 340 and the space between slider 340and second body 360. Thermal fluid 105 can also flow throughsecond-spool opening 375 between this space and the cavity of secondspool 370. In other words, in this state, a fluidic pathway is providedbetween the cavity inside slider 340 and the cavity of second spool 370thereby allowing the flow of thermal fluid 105 through fluidic coupling300. At the same time, first spool 320 remains sealed against first body310 by first seal 315 also against second body 360 by second seal 365thereby sealing the interface between first body 310 and second body360.

When fluidic coupling 300 is in the decoupled state, e.g., as shown inFIG. 3B, first spool 320 is sealed relative to slider 340 by firstslider seal 345 thereby blocking the flow of thermal fluid 105 fromfirst component 301. First spool 320 remains sealed against first body310 by first seal 315. Furthermore, second spool 370 is sealed relativeto second body 360 by second seal 365 thereby blocking the flow ofthermal fluid 105 from second component 302. The transition between thecoupled state and decoupled state is described below with reference toFIG. 4 and FIGS. 5A-5F below.

Examples of Methods of Operating Battery Modules

FIG. 4 is a process flowchart corresponding to method 400 of operatingbattery module 120, in accordance with some examples. Method 400 maycommence with (block 410) installing battery module 120 on electricvehicle 100. For example, electric vehicle 100 can include a bay forreceiving battery module 120. During this installation operation,battery module 120 forms an electrical connection with electric vehicle100 using first electrical terminal 241 and second electrical terminal242. For example, electric vehicle 100 can include correspondingterminals configured to connect with first electrical terminal 241 andsecond electrical terminal 242. In some examples, battery module 120forms a mechanical connection with electric vehicle 100 (e.g., lockedusing a latching mechanism). Furthermore, in some examples, installingbattery module 120 on electric vehicle 100 comprises (block 412) forminga fluidic coupling between battery module 120 and electric vehicle 100,e.g., using first fluidic port 251 and second fluidic port 252 ofbattery module 120. One example of such coupling is shown and describedabove with reference to FIGS. 3A and 3B. Additional features aredescribed below with reference to FIGS. 5A-5F below. This fluidiccoupling is optional, and, in some examples, battery module 120 is notfluidically connected to electric vehicle 100.

Method 400 may proceed with (block 420) operating electric vehicle 100,e.g., by powering electric vehicle 100 from battery module 120. As aresult, battery module 120 is discharged during this operation. Itshould be noted that, in some examples, battery module 120 may be alsocharged onboard electric vehicle 100. In some examples (when batterymodule 120 is fluidically connected to electric vehicle 100), operatingelectric vehicle 100 may comprise (block 422) circulating thermal fluid105 through battery module 120. For example, electric vehicle 100 mayinclude vehicle thermal management system 110, which is designed tocondition the temperature of thermal fluid 105 (e.g., by heating and/orcooling thermal fluid 105) and to pump thermal fluid 105 through batterymodule 120. In some examples, battery module 120 and electric vehicle100 can be communicatively coupled during this operation. For example,battery module 120 can measure the internal cell temperature and sendthis information to vehicle thermal management system 110.

Method 400 may proceed with (block 430) removing battery module 120 fromelectric vehicle 100. This operation may be the reverse of theinstallation operation (block 410) described above. During the moduleremoval operation, the electrical connection between battery module 120and electric vehicle 100 is separated (e.g., by disconnecting firstelectrical terminal 241 and second electrical terminal 242 from thecorresponding terminals on electric vehicle 100). In some examples (whenbattery module 120 is fluidically connected to electric vehicle 100),the battery removal operation (block 430) also comprises (block 432)disconnecting the fluidic coupling between battery module 120 andelectric vehicle 100 as will now be described with reference to FIGS.5A-5F.

Specifically, FIG. 5A illustrates fluidic coupling 300 is in the coupledstate, which is described above with reference to FIG. 3A. FIG. 5Billustrates the first step in this disconnecting operation where firstbody 310 is moved away from second body 360. First spool 320 is biasedby first spring 350, which pushes first spool 320 out of first body 310.At this step, second body 360 is operable as a positive stop for firstspool 320. In fact, second body 360 is operable as a positive stop forfirst spool 320 during the coupled state in FIG. 5A and the next/secondstep in FIG. 5C. Referring to FIG. 5B, slider 340 follows first body 310and is retracted into first spool 320. At this step, first slider seal345 is not contacting/sealed against first spool 320 thereby allowingthermal fluid 105 to flow (through slider opening 343) between thecavity inside slider 340 and the space between slider 340 and secondbody 360. At the same time, as slider 340 follows first body 310 and isretracted into first spool 320, second spool 370 is biased toward firstspool 320. FIG. 5B illustrates a point where second spool 370 reachesand contacts first spool 320. From this point on, first spool 320 isoperable as a positive stop for second spool 370, at least through thefew steps described below. In the coupled state of FIG. 5A, slider 340acted as a positive stop for second spool 370. This spool contact canrestrict the flow of thermal fluid 105 (in comparison to the coupledstate of FIG. 5A) but does not fully seals the flow.

FIG. 5C illustrates the second step in this disconnecting operationwhere first body 310 is moved further away from second body 360 (incomparison to the first step of FIG. 5B). Slider 340 follows first body310 and is retracted into first spool 320. However, at this step, firstslider seal 345 is sealed against first spool 320 thereby preventingthermal fluid 105 to flow between the cavity inside slider 340 and thespace between slider 340 and second body 360. First spool 320 continuesbeing pushed out of first body 310 by first spring 350 with second body360 still operable as a positive stop.

FIG. 5D illustrates the third step in this disconnecting operation wherefirst body 310 is moved further away from second body 360 (in comparisonto the second step of FIG. 5C). First slider seal 345 remains sealedagainst first spool 320 thereby preventing the flow of thermal fluid105. First spool 320 is no longer being pushed out of first body 310since a feature of first body 310 is now operable as a positive stop forfirst spool 320. As such, first spool 320 is now being extracted fromsecond body 360. However, second seal 365 still seals against firstspool 320 at this stage.

FIG. 5E illustrates the fourth step in this disconnecting operationwhere first body 310 is moved further away from second body 360 (incomparison to the second step of FIG. 5D). First slider seal 345 remainssealed against first spool 320 thereby preventing the flow of thermalfluid 105. First spool 320 continues being extracted from second body360. The specific point (shown in FIG. 5E) can be referred to as the“second seal handoff” where second seal 365 disengages first spool 320and engages second spool 370, which follows the travel of first spool320.

Finally, FIG. 5F illustrates the decoupled state where first body 310 ismoved even further away from second body 360 (in comparison to thesecond step of FIG. 5E). This decoupled state is described above withreference to FIG. 3B.

Returning to FIG. 4 , method 400 may proceed with (block 440) installingbattery module 120 on external charger 180. For example, thisinstallation operation may comprise (block 441) positioning swappablebattery module 120 on external charger 180 comprising charger fluidicports 183. One example of external charger 180 is shown in FIGS. 6A-6E.It should be noted that a module connection on electric vehicle 100 maybe configured in a similar manner and include the same components.

FIGS. 6A and 6B illustrate external charger 180 suitable for connectingto four battery modules 120. However, only one battery module 120 isshown in these views. External charger 180 comprises charger base 181,providing four module bays (one for each battery module 120). Eachmodule bay comprises module support rail 184, two charger fluid ports183, and two charger electric terminals 189. Module support rail 184 isconfigured to support battery module 120 and allow battery module 120 toslide in and out of the module bay while forming electric and fluidconnections with external charger 180. Two charger fluid ports 183 arealigned (e.g., concentrically aligned) with corresponding fluid ports250 of battery module 120 while battery module 120 is positioned onmodule support rail 184.

Each module bay also comprises limiting arm 185 pivotably coupled (atpivot point 187) to charger enclosure 186. Limiting arm 185 compriseslimiting bar 188 positioned on the arm end proximate to charger base181. Pivoting the limiting arm 185 changes the distance between limitingbar 188 and charger base 181 as will now be described with reference toreference to FIGS. 6C-6E.

Method 400 may proceed with (block 430) sliding first end plate 150 ofbattery module 120 toward charger fluidic ports 183 until chargerfluidic ports 183 are fluidically coupled with first fluidic port 251and second fluidic port 252. In other words, this sliding operation alsocomprises (block 442) connecting the fluidic coupling or, morespecifically, connecting fluidic ports 250 of battery module withcharger fluidic ports 183.

FIG. 6C is a schematic side view of external charger 180 without batterymodule 120, in which limiting arm 185/limiting bar 188 is in the firstposition (further away from charger base 181). As battery module 120slides on support rail 184 toward charger base 181, battery module 120first contacts limiting bar 188 (e.g., as shown in FIG. 6D) thatprevents battery module 120 from hitting charger base 181 and, morespecifically, prevents corresponding fluid ports 250 of battery module120 from hitting charger fluid ports 183 and, also, correspondingelectric terminals 240 of battery module 120 from hitting chargerelectric terminals 189. It should be noted that battery module 120 isquite heavy and can carry significant momentum while sliding on supportrail 184. It should be also noted that limiting bar 188 is positionedsuch that neither fluid ports 250 nor electric terminals 240 contactlimiting bar 188 during this stage.

FIG. 6E is a schematic side view of external charger 180 with limitingarm 185/limiting bar 188 being in the position (closer to charger base181). As limiting bar 188 transitions from the first position (in FIG.6D) to the second position (in FIG. 6E), battery module 120 is allowedto get closer to charger base 181 and form the electric and fluidiccoupling with external charger 180.

Method 400 may proceed with (block 450) charging battery module 120 onexternal charger 180. As a result, battery module 120 is charged duringthis operation. In some examples (when battery module 120 is fluidicallyconnected to external charger 180), this charging operation may comprise(block 452) circulating thermal fluid 105 through battery module 120.For example, external charger 180 may include charger thermal managementsystem 190, which is designed to condition the temperature of thermalfluid 105 (e.g., by heating and/or cooling thermal fluid 105) and topump thermal fluid 105 through battery module 120. In some examples,battery module 120 and external charger 180 can be communicativelycoupled during this operation. For example, battery module 120 canmeasure the internal cell temperature and send this information tocharger thermal management system 190.

Method 400 may proceed with (block 460) removing battery module 120 fromexternal charger 180. This operation may be the reverse of theinstallation operation (block 440) described above. During the moduleremoval operation, the electrical connection between battery module 120and external charger 180 is separated (e.g., by disconnecting firstelectrical terminal 241 and second electrical terminal 242 from thecorresponding terminals on electric vehicle 100). In some examples (whenbattery module 120 is fluidically connected to external charger 180),the battery removal operation (block 460) also comprises (block 462)disconnecting the fluidic coupling between battery module 120 andexternal charger 180 in a manner similar to the one described above withreference to FIGS. 5A-5F.

CONCLUSION

Although the foregoing concepts have been described in some detail forpurposes of clarity of understanding, it will be apparent that certainchanges and modifications may be practiced within the scope of theappended claims. It should be noted that there are many alternative waysof implementing processes, systems, and apparatuses. Accordingly, thepresent examples are to be considered illustrative and not restrictive.

What is claimed is:
 1. A swappable battery module comprising: prismaticbattery cells comprising a first-end cell and a second-end cell,wherein: the prismatic battery cells are stacked along a primary axis ofthe swappable battery module between the first-end cell and thesecond-end cell, the prismatic battery cells comprise first surfaces,second surfaces opposite to the first surfaces, and side surfacesextending between the first surfaces and the second surfaces, and theprismatic battery cells comprise cell terminals positioned on the firstsurfaces; bus bars forming at least a first bus-bar row and a secondbus-bar row and interconnecting the cell terminals; a tubular enclosure,attached to each of the first surfaces, the second surfaces, and theside surfaces of the prismatic battery cells, wherein: the tubularenclosure forms a first fluid channel and a second fluid channel with aportion of the first surfaces such that the first bus-bar row extendswithin the first fluid channel while the second bus-bar row extendswithin the second fluid channel, and the tubular enclosure forms a thirdfluid channel and a fourth fluid channel with a portion of the secondsurfaces; a first end plate attached to the tubular enclosure andcomprising: a first fluidic port fluidically coupled to both the firstfluid channel and the third fluid channel, a second fluidic portfluidically coupled to both the second fluid channel and the fourthfluid channel, and a first electrical terminal and a second electricalterminal electrically coupled to the bus bars; and a second end plateattached to the tubular enclosure, fluidically interconnecting the firstfluid channel and the third fluid channel, and fluidicallyinterconnecting the second fluid channel and the fourth fluid channel,wherein: each of the first fluidic port and the second fluidic port isconfigured to form a fluidic coupling with a corresponding fluidic porton one or both of an electric vehicle and an external charger, thefluidic coupling comprises a first component and a second component,configured to form a sealed fluidically coupling with each other in acoupled state and to disconnect from each other while transitioning intoa decoupled state; the first component comprises a first body, a firstseal, a first spool, a first spool seal, a slider, a first slider seal,and a first spring; the first spool is slidably coupled to the firstbody and to the slider and biased, relative to the first body, by thefirst spring; the first spool is sealed against the first body by thefirst seal; the second component comprises a second body, a second seal,a second spool, and a second spring; the second spool is slidablycoupled to and biased, by the second spring, relative the second body;when the fluidic coupling is in the coupled state, the first spoolextends into the second body and is sealed against the second body bythe second seal; and when the fluidic coupling is in the decoupledstate, the first spool is sealed relative to the slider by the firstslider seal while the second spool is sealed relative to the second bodyby the second seal.
 2. The swappable battery module of claim 1, whereinthe tubular enclosure comprises a first enclosure portion and a secondenclosure portion, each independently attached to each of the firstsurfaces, the second surfaces, and the side surfaces of the prismaticbattery cells and further attached to each of the first end plate andthe second end plate.
 3. The swappable battery module of claim 2,wherein: the tubular enclosure further comprises an interconnectingportion, attached to each of the first enclosure portion and the secondenclosure portion and forming a gas-ventilation channel with the firstsurfaces of the prismatic battery cells, and the prismatic battery cellscomprise pressure-release burst valves positioned on the first surfacesand in fluid communication with the gas-ventilation channel.
 4. Theswappable battery module of claim 3 further comprising sensor wires,functionally coupled to each of the prismatic battery cells andprotruding within the gas-ventilation channel to the first end plate. 5.The swappable battery module of claim 1 further comprising a handlecoupled to the tubular enclosure, proximate to the second surfaces ofthe prismatic battery cells such that prismatic battery cells arepositioned between the bus bars and the handle.
 6. The swappable batterymodule of claim 1, wherein: a portion of the first end plate protrudesinto and is glued to the tubular enclosure; and a portion of the secondend plate protrudes into and is glued to the tubular enclosure.
 7. Theswappable battery module of claim 1, wherein: the first end plate isglued to the first-end cell; and the second end plate is glued to thesecond-end cell.
 8. The swappable battery module of claim 1, wherein:the tubular enclosure is glued to each of the first surfaces, the secondsurfaces, and the side surfaces of each of the prismatic battery cells;and the tubular enclosure is electrically isolated from each of theprismatic battery cells.
 9. The swappable battery module of claim 1,wherein each adjacent pair of the prismatic battery cells ismechanically interconnected by an adhesive layer extending between theprismatic battery cells in each adjacent pair.
 10. The swappable batterymodule of claim 9, wherein the adhesive layer has an annulus shape. 11.The swappable battery module of claim 1, wherein: the bus bars form atleast a third bus-bar row extending within the second fluid channel, oneof the bus bars in the first bus-bar row is electrically coupled to thefirst electrical terminal, and one of the bus bars in the third bus-barrow is electrically coupled to the second electrical terminal.
 12. Theswappable battery module of claim 1, wherein each of the first bus-barrow and the second bus-bar row comprises multiple disjoined components.13. The swappable battery module of claim 12, wherein: each of themultiple disjoined components comprises two planar portions and aninterconnecting rib, joining the two planar portions, the two planarportions are connected to the cell terminals of two adjacent ones of theprismatic battery cells, the interconnecting rib protruding from the twoplanar portions and in a direction away from the prismatic battery cellsand comprises one or more fluid path openings.
 14. The swappable batterymodule of claim 1, wherein: the first end plate comprises a centerprotrusion and two side edges, extending along the side surfaces of thefirst-end cell, and the two side edges and the center protrusion formedge channels fluidically coupling the first fluid channel and the thirdfluid channel and, separately, fluidically coupling the second fluidchannel and the fourth fluid channel.
 15. The swappable battery moduleof claim 1 further comprising: sensor wires functionally coupled to eachof the prismatic battery cells; and a battery management system,electronically coupled to each of the sensor wires, wherein: the firstend plate comprises an outer cavity such that the battery managementsystem is positioned with the outer cavity, and the first end platefurther comprises a passthrough such that the sensor wires protrudethrough the passthrough and are sealed within the passthrough.
 16. Theswappable battery module of claim 1, wherein the second end platecomprises: a first cavity fluidically coupling the first fluid channeland the second fluid channel, and a second cavity fluidically couplingthe third fluid channel and the fourth fluid channel.
 17. The swappablebattery module of claim 1, wherein each of the first fluidic port andthe second fluidic port is the second component of the fluidic coupling.18. A method of operating a swappable battery module, the methodcomprising: positioning the swappable battery module on an externalcharger comprising charger fluidic ports, wherein: the swappable batterymodule comprises prismatic battery cells, a tubular enclosure, attachedto and enclosing the prismatic battery cells, a first end plate attachedto the tubular enclosure, and a second end plate attached to the tubularenclosure, the tubular enclosure forms a first fluid channel, a secondfluid channel, a third fluid channel, and a fourth fluid channel withthe prismatic battery cells, the first end plate comprises a firstfluidic port, fluidically coupled to both the first fluid channel andthe third fluid channel, and a second fluidic port, fluidically coupledto both the second fluid channel and the fourth fluid channel, and thesecond end plate fluidically interconnects the first fluid channel andthe third fluid channel and, separately, fluidically interconnects thesecond fluid channel and the fourth fluid channel; and sliding the firstend plate toward the charger fluidic ports until each of the chargerfluidic ports forms a fluidic coupling with each of the first fluidicport and the second fluidic port, wherein: the fluidic couplingcomprises a first component and a second component, configured to form asealed fluidically coupling with each other in a coupled state and todisconnect from each other while transitioning into a decoupled state;the first component comprises a first body, a first seal, a first spool,a first spool seal, a slider, a first slider seal, and a first spring;the first spool is slidably coupled to the first body and to the sliderand biased, relative to the first body, by the first spring; the firstspool is sealed against the first body by the first seal; the secondcomponent comprises a second body, a second seal, a second spool, and asecond spring; the second spool is slidably coupled to and biased, bythe second spring, relative the second body; when the fluidic couplingis in the coupled state, the first spool extends into the second bodyand is sealed against the second body by the second seal; and when thefluidic coupling is in the decoupled state, the first spool is sealedrelative to the slider by the first slider seal while the second spoolis sealed relative to the second body by the second seal.
 19. The methodof claim 18, wherein the second component corresponds to each of thefirst fluidic port and the second fluidic port.
 20. The method of claim18, wherein sliding the first end plate toward the charger fluidic portsfurther forms an electrical connection between the swappable batterymodule and the external charger.